2007 Husqvarna SM 610 / TE 610 I.E. Factory Service & Repair Manual (P/N 8000 A7918)

This Husqvarna workshop manual covers the 2007 SM 610 and TE 610 I.E. in 39 kW and 22 kW versions. Publication 8000 A7918, 1st Edition (02-2007), documents maintenance, diagnosis, and repair.

The download contains one 503-page A4 PDF with Italian, English, French, German, and Spanish text. Searchable workshop text appears alongside image-based diagrams.

• Engine and drivetrain repair: Engine removal, teardown, inspection, and reassembly, including the cylinder head, valves, piston, crankshaft, balance shaft, clutch, and six-speed transmission.

• Suspension overhaul: Marzocchi USD fork service and damping changes, plus Sachs shock, reservoir, diaphragm, spring, swingarm, rocker, and linkage overhaul.

• EFI and electrical diagnosis: Connector tests, charging, starting and ignition checks, fuel-pump and relay testing, and SM/TE digital-instrument setup.

• Brakes, wheels, and chassis: Disc and pad inspection/replacement, hydraulic bleeding, wheel bearings, spoke and rim checks, chain and sprocket service, steering adjustment, and frame inspection.

• Service data: Pre-delivery and periodic maintenance schedules, troubleshooting charts, torque tables, approved fluids, capacities, assembly clearances, wear limits, suspension settings, and electrical test specifications.

Husqvarna wrote this manual for its workshops and authorized personnel, with repair experience and the specified tools needed for the overhaul and diagnostic work.

Engine and Drivetrain Repair

Separate disassembly, inspection, and reassembly chapters take the single-overhead-cam, four-valve engine through bench repair. Inspection covers valve seats and guides, rocker-arm bushings, cam rollers, piston-to-cylinder fit, connecting-rod and crankshaft condition, clutch wear, and gear-selector clearances.

Assembly coverage includes crankcase sealing, crankshaft and transmission installation, starter/freewheel drive, cam timing, balance-shaft timing, clutch setup, and final system connections. Oil-pump, filter, and water-pump service procedures accompany these chapters.

Cooling sections explain thermostat, fan, and expansion-tank operation, with radiator and hose inspection and coolant replacement.

Listed tools include crankcase puller 8000 89743, flywheel puller 8000 39523, engine holder 8000 90662, clutch-hub holding wrench 8000 39524, and TDC control tool 8000 90875. These references let a shop check tooling requirements before starting an engine repair.

SM and TE Chassis Differences

The factory validity table gives these starting VINs:

• SM 39 kW: ZCGA1AFEKP7V400000
• SM 22 kW: ZCGA101AB7006000
• TE 39 kW: ZCGA1EAEKP7V300000
• TE 22 kW: ZCGA101AA7006000

The TE entries are labeled “TE 610 E.” The repair chapters share powertrain procedures across the power versions.

SM/TE differences cover front brakes, wheels, final-drive chain length, fork travel and spring selection, shock rebound settings, headlamp service, instrument parameters, and the SM-only tilt sensor.

Marzocchi fork: Troubleshooting and overhaul extend to oil and seals, air bleeding, sliders, stanchions, damper teardown and reassembly, and compression/rebound damping-stack changes.

Sachs shock: Procedures address internal inspection, reservoir and diaphragm replacement, oil filling, bleeding, gas charging, and damping adjustment. The section warns that substituting different compression blades can cause the shock to burst in use.

EFI, Electrical, and Diagram References

Electrical chapters combine component locations and harness routing with open/short-circuit checks, meter use, generator and regulator-rectifier tests, battery service, lighting, and switch checks.

EFI coverage identifies water-temperature and O2 sensors, the M.A.Q.S. pressure/TPS/air-temperature unit, gear-position and battery signals, injector, ignition coil, and O2 heater.

Diagnosis Software Kit 8000 A9634: The manual explains connection and current/stored-fault diagnosis. TPS idle adjustment, feedback adjustment, and fault-memory clearing refer to the kit’s separate Operation Manual. The kit, PC software, interface cable, and separate Operation Manual are not included.

Illustrated references include the main wiring diagram and cable-color key, generator test diagram, starter-relay diagram, cooling-system circuit, dual-pump lubrication schematic, and frame measurement drawing.

Electrical precautions address ECU and injection-component damage from reversed battery polarity or battery disconnection while the engine runs. Brake bleeding, pressurized cooling systems, and gas-charged shock work require the factory precautions and suitable workshop equipment.

PDF Format and Readability

Page count: One cover page and one copyright/edition page are included in the 503-page total. The remaining 501 numbered manual pages include the foreword, contents, chapter dividers, and seven otherwise blank pages. No separate supplement is supplied.

Navigation: Printed section contents are provided; embedded PDF bookmarks are absent.

Search and diagrams: Text search works in the workshop text and diagram legends, but not inside the raster wiring diagrams. Wire-color codes need zoom, and some tiny ECU and instrument connector numbers remain blurred when enlarged.